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  • C62, C76, C59-10, C58-12, C57-14

    Deutz M1011FPowered Compressor

    Id. Nr. 100 001 897 / 04 - Mrz 2003

    Operating Manual

    GB

  • 61

    1.1 Information on the compressor

    CompAir screw compressors are theproduct of many years' research anddevelopment. These preconditions,together with high quality standards,guarantee the manufacture of screwcompressors with a long service life, a highdegree of reliability and cost-effectiveoperation. The strict environmentalprotection standards have of course beencomplied with.

    Confirmation of Conformity The compressor and its accessories

    conform to the safety requirements laidout in the EC Directives 89/392 and95g368 EEC and in EN 474-1.

    Fig. 1

    1.2 Normal use

    The compressors have been built usingthe latest techniques in design and inaccordance with recognized safetyregulations.

    Nevertheless, the operator or third partiesmay be exposed to risk to life and limb inthe course of the use of the compressor(e.g. through flying pieces of buildingmaterial, swirling particles of dirt or dust,electrical current, thermal vibrations, noiseor mechanical hazards), and the machineor other tangible assets may be impaired,for reasons that could not have beenavoided through preventive constructionalsafety measures.Hazards occur particularly when:* The compressor is not used for its

    intended purpose* The compressor is not operated by

    trained personnel* Unauthorized changes or modifications

    are carried out on the compressor* You are not wearing the prescribed

    protective clothing* You do not comply with the safety

    instructions

    * You do not observe the information inthe operating manual

    For this reason every person involved inthe operation, maintenance and repair ofthe compressor must read and observethe operation manual and the safetyregulations. This is to be confirmed bysignature as required.Furthermore, the following naturally apply:* The relevant accident prevention

    regulations* Generally recognized safety and traffic

    regulations* Particular national regulationsThe compressor is designed for providingcompressed air:* For operating compressed-air

    appliances* For conveying bulk material* For sandblasting and paint-spraying

    operations* For cleaning machines and shuttering

    material - do not direct towards persons!* For blow-cleaning drilled holes.

    Any other use, or any additional use,for example as respiratory air, is regardedas not being for the originally intendedpurpose. The manufacturer / supplieraccepts no liability for any resultingdamage. The risk is assumed by the useralone.

    The compressor may only be used ina technically perfect condition, for itsintended purpose, with appropriateawareness of safety regulations andhazards, subject to compliance with theoperating manual. In particular, faultsrepresenting safety hazards are to becorrected at once.

    1. Foreword

  • 62

    1. Foreword

    1.3 Specifications type DLT 0702

    [kg] [kg] [mm] [mm] [mm] [bar] [dB/1 pW] [dB(A)] [dB(A)]

    C 62 1300 1100 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 100 83 71

    C 62 G 1300 1175 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 101 84 72

    C 62 HS 1300 1100 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 101 84 72

    C 76 1300 1100 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 101 84 72

    C 76 G 1300 1175 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 101 84 72

    C 59-10 1300 1100 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 101 84 72

    C 59-10 G 1300 1175 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 101 84 72

    C 58-12 1300 1100 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 101 84 72

    C 57-14 1300 1100 3770 1580 1415 5 1/2 J x 14 185 R 14 2.8 101 84 72

    Ambient Enginetemperature speed

    min. max. No-load On-load

    [m3/min] [bar] [bar] [C] [C] [m] [l] [kW] [rpm] [rpm] [l] [l]

    C 62 6.2 7 5 - 8 -10 +50 1000 14 F4M1011F Oil 43.3 1450 2600 10 120

    C 62 G 6.2 7 5 - 8 -10 +45 1000 14 F4M1011F Oil 43.3 1450 2600 10 120

    C 62 HS 6.2 7 5 - 8 -10 +50 1000 14 BF4M1011F Oil 61 1650 2800 10 120+40 3000

    C 76 7.6 7 5 - 8 -10 +50 1000 14 BF4M1011F Oil 61 1650 2800 10 120

    C 76 G 7.6 7 5 - 8 -10 +45 1000 14 BF4M1011F Oil 61 1650 2800 10 120

    C 59-10 5.9 10 5 - 10 -10 +50 1000 14 BF4M1011F Oil 61 1650 2800 10 120

    C 59-10 G 5.9 10 5 - 10 -10 +45 1000 14 BF4M1011F Oil 61 1650 2800 10 120

    C 58-12 5.8 12 5 - 12 -10 +45 1000 14 BF4M1011F Oil 61 1650 2800 10 120

    C 57-14 5.7 14 5 - 14 -10 +45 1000 14 BF4M1011F Oil 61 1650 2800 10 120

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  • 63

    1.4 Maintenance and care

    Care and maintenance are all-importantif the screw compressor is to meet thedemands placed upon it. Compliance withthe prescribed maintenance intervals andcareful execution of care and maintenancework are therefore essential, especiallyunder difficult working conditions.

    ServiceIn case of faults, or should you require

    spare parts for the screw compressor,please contact your local CompAir agent.

    In case of damage, the trained technicalstaff will guarantee a fast, expert repairusing CompAir spare parts. OriginalCompAir spare parts are manufacturedaccording to the state of the art andguarantee continued reliable operation.

    If you have important questions,

    Fig. 2Please enter the data from the identifi-

    cation plate for your compressor, in thespaces above. In case of questions ororders for spare parts, please give us thecompressor type, compressor numberand the year of construction as given onthe identification plate.If you give us this data you can be sure thatyou will be given the correct information orsent the spare parts you require.

    Auftrags-Nr., order number,numro de commande, numero d'ordine

    Typ, type, modle, tipo

    Volumenstrom, flow rateflux volumique, flusso volumetrico

    Stufendrcke, stages pressures,pression d'etages, pressioni degli stadi di compressione

    Drehzahl, revolutions per minute,rgime de rotation, numero dei giri

    Installierte Motorleistung, installed engine power,puissance moteur installe, pressione di aspirazione

    Ansaugdruck, intake pressure,pression d'aspiration, pressione d'aspirazione

    m3/min

    bar

    min-1

    kW

    bar

    max. Sttzlast an Kupplung, max. tongue load at

    coupling, charge d'appui l'attelage,carico di appoggio massimo sulla frizione

    Baujahr, year,anne, anno

    N

    Handelsbezeichnung, trade name, dnominationcommerciale, denominazione commerciale

    7

    9

    10

    11

    8

    6

    4

    5

    2

    3

    1

    CompAir Drucklufttechnik GmbHWerk 55469 Simmern

    1. Foreword

    1.5 General information

    This operating manual is to help you toget to know the compressor and to use itfor its intended applications. It containsimportant information about how to operatethe compressor safely, cost-effectivelyand with due care. Compliance with theinstructions in this manual will help to avoiddanger, reduce repair costs and downtime,and increase the reliability and service lifeof the compressor.

    This operating manual is to besupplemented by instructions concerningcurrent national regulations for accidentprevention and environmental protection. Itmust always be available at the site of thecompressor. The operating manual is to beread and used by all persons in charge ofwork with the compressor, for exampleoperation, including setting up, correctingfaults during operation, disposal of wasteproducts from production, care, disposal ofprocess materials, upkeep (maintenance,inspection, repair) and transport.

    Besides the operating instructions andthe current regulations applicable in theuser's country and at the sites of operationconcerning accident prevention, therecognized technical rules for safe andproper working are also to be compliedwith.

    WarrantyOnly use this compressor with accurate

    knowledge of and in compliance with thismanual.

    CompAir Drucklufttechnik GmbHdo not accept responsibility for safefunctioning of the compressor for actionsthat do not correspond to normal use or forpurposes not mentioned in the manual.Warranty claims cannot be entertained for:* Operating errors* Inadequate maintenance* Incorrect fuels

    * Damage caused by non-use of originalCompAir parts

    * Modification of the system.The Guarantee and Liability terms of

    CompAir's General Terms and Conditionsare not extended through the aboveinstructions.

    Any unauthorized modification of thecompressor system/station or theinstallation of components (e.g. fineseparators) not released by themanufacturer result in the loss of theCE symbol.

    This fact results in the termination/expiration of the guarantee and warrantyclaims against the manufacturer.

    Safety regulations

    DangerIt is important that you follow the safetyregulations in Chapter 3 of the operatingmanual.

    Technical modificationsWe reserve the right to undertake

    modifications without notice in the interestsof technical progress.

  • 64

    2. Index

    1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611.1 Information on the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611.2 Normal use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611.3 Specifications type DLT 0702 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621.4 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631.5 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

    2. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

    3. Security regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663.1 Identification of safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663.3 Modifications and alterations to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663.4 Loading / Relocation / Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673.5 Installation on site / Starting / Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673.6 Special jobs / Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693.7 Instructions concerning particular hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 713.8 Symbols and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

    4. Construction and functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764.1 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764.3 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 784.4 Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 794.5 Terminal Diagram DIN ISO 1724 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

    5. Transport and installation on site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815.2 Link up breakaway cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815.3 Loading / Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815.4 Installation on site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

    6. Preparing the compressor for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 846.1 Checking oil levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

    6.1.1 Checking pressure tank oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 846.1.2 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

    6.2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 846.3 Filling up the fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 846.4 Checking the air filter maintenance display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

    7. Putting the compressor into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 867.1 Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 867.2 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 867.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 867.4 Setting the operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 877.5 Monitoring / fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 877.6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 887.7 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 887.8 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

    8. Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908.1 Recommended lubricant for compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908.2 Recommended engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908.3 Tool lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908.4 Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908.5 Recommended lubricants for the bogies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

  • 65

    9. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 919.1 General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 919.2 Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 919.3 Maintenance of chassis and brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 919.4 Compressor maintenance / Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

    9.4.1 Oil filter replacement (compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 939.4.2 Oil change (compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 939.4.3 Checking the automatic monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 939.4.4 Inspecting / Replacing the fine separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 939.4.5 Air filter replacement (compressor / engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 949.4.6 Checking the safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 949.4.7 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 959.4.8 Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 959.4.9 Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

    10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

    11. Generator option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9811.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9811.2 Generator safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9811.3 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9811.4 Operating the generator (Working safely with electrical equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9911.5 Testing insulation monitoring/startup/device connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10011.6 Technical characteristics of 8 kVA 400/230 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10111.7 Technical characteristics of 12 kVA 400/230 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10211.8 Technical characteristics of 7 kVA 110 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10211.9 Generator switchbox wiring diagram of 8 kVA and 12 kVA 400/230 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10411.10 Generator switchbox wiring diagram of 7 kVA 110 V generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10411.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

    12. Heat exchanger option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10712.1 Safety regulations for the use of the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10712.2 Design and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10712.3 Maintenance / Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10712.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

    13. Compressed air processing option (After cooler / Filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10813.1 Safety regulations for alternate compressed air processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10813.2 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10813.3 Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10813.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

    14. Breathing air connection option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10914.1 Notes on safety and description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

    15. Oil temperature controller option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11015.1 Safety regulations for the use of an oil temperature controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11015.2 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11015.3 Maintenance / care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11015.4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

    16. Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11116.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11116.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11116.3 KHV13 height-adjustable towing system, model B 3.5.13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11116.4 Braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11116.5 Adjusting the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11216.6 Readjusting the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11316.7 Maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11316.8 Malfunctions and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

    17. Tool oiler option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

    2. Index

  • 66

    3.1 Identification of safetyinstructions

    CompAir accepts no responsibility forany damage or injury caused by non-compliance with these safety measures ornon-observance of normal care andcaution during the handling, operation,maintenance or repair of this compressor,even if not expressly stated in thisoperating manual.

    If any of the regulations contained inthis manual do not correspond to localstatutory provisions, particularly withreference to safety, then the stricter ofthe two applies.

    These safety instructions are of a generalnature and are applicable to various typesof machine and equipment. For this reasonit is possible that some information may notapply to the aggregate(s) described in thismanual.

    DangerPlaces thus marked refer to possibledangers for persons.

    Attention

    Places thus marked refer to possibledangers for machines or parts ofmachines.

    Note

    Places thus marked give general andtechnical information for optimum, cost-effective machine use.

    3.2 General safety instructions

    Organizational measuresPlease keep this operating manual handy

    at all times on the site of the machine /installation, in the bag provided.

    Please note and pass on generalstatutory and other binding regulationsthat may supplement the operatingmanual for the prevention of accidentsand the protection of the environment.Such obligations may be for example thehandling of hazardous materials, or theprovision and/or wearing of personalprotective equipment, or traffic regulations.

    Instructions, including supervisoryresponsibility and duty of notification fortaking account of special in-plant factors,for example regarding work organization,sequences of operations, personnelassigned to certain tasks, are to be addedto the operating manual.

    Personnel delegated to work with themachine must have read the operatingmanual before beginning this work,particularly the chapter on safetyinstructions. It is too late to do this whileworking. This applies particularly topersonnel only using the machineoccasionally, e.g. for setting up andmaintaining the machine.

    Safety and danger-conscious workingby the personnel in compliance with theoperating manual should be checked atleast occasionally.

    The personnel must not have long, loosehair, or wear loose clothing or jewellery,including rings, due to risk of injury throughcatching. Personal protective equipmentshould be worn if necessary or as requiredby regulations.

    Pay attention to all safety and dangerwarnings on the machine/ installation!

    Make sure that all safety and dangerwarnings on the machine / installation canbe read.

    For all safety-relevant modifications tothe machine / installation or its operatingbehavior, stop the machine / installationimmediately and report the fault to thecompetent authority / person.

    Spare parts must meet the technicalrequirements laid down by themanufacturer. This is always guaranteedwhen original spare parts are used.

    Replace hydraulic hoses at the givenintervals, or at suitable intervals, even ifno safety-relevant defects are visible(DIN 20066, Part 5).

    Observe the intervals stipulated or thosegiven in the operating manual for routinechecks and inspections.

    Workshop equipment suitable for carryingout maintenance work is essential.

    The location and operation of fireextinguishers must be made known.Observe the instructions concerning firealarm and firefighting.

    Limiting values (pressure, temperature,time settings etc.) must be permanentlymarked.

    Personnel selection and qualification;basic tasks

    Work on or with the machine / installationmay only be carried out by reliablepersonnel. Observe the minimum statutoryage.

    Only trained or specially instructedpersonnel may be assigned to this work.The responsibility of the personnel foroperating, setting up, maintaining andrepairing the machine / installation mustbe clearly defined.

    Make sure that only authorized personneluse the machine.

    Define who is responsible for operatingthe machine, and authorize him to ignoreinstructions from third parties if theseinstructions could compromise safety.

    Only allow personnel that are training,that are under instruction or are attendinga course of general training to use themachine / installation under the constantsupervision of an experienced person.

    Work on the electrical systems of themachine / installation may only be carriedout by a trained electrician in accordancewith electrical regulations.

    Only persons with special knowledge andexperience of hydraulics may work onsystem elements, for example componentsunder pressure.

    3.3 Modifications and alterationsto the machine

    No alterations, additions, or modificationsto the machine may be carried out withoutthe approval of the manufacturer. Thisis also true for the installation and theadjustment of safety devices and valvesas well as for welding at supportingand pressurized parts. Unauthorizedmodifications to the machine are prohibitedfor reasons of safety.

    Original parts are specially designed forour machines. We must explicitly point outthat parts and special accessories notsupplied by us are not approved by us.Installing or using such products may thusadversely affect active and/or passivesafety.

    The manufacturer accepts no liabilitywhatsoever for damage resulting from theuse of non-original parts or specialaccessories. This also applies to theinstallation and adjustment of safetydevices and valves as well as to weldingon bearing and pressurized parts.

    Note

    The General Type Approval becomes inva-lid in case of modifications or alterationswhich change or infringe upon the externalgeometry as well as the gross axle weightrating.

    3. Security Regulations

  • 67

    3.4 Loading / Relocation / Transport

    Loading / RelocationAll loose parts that could fall down when

    the machine is lifted must first be removedor secured; pivoting parts like doors, etc.must be immobilized.

    For lifting heavy parts, hoisting gear andheavy-lift facilities with the appropriatecapacities, which have been checked andapproved in accordance with local safetyregulations, must be used.

    For lifting machines or parts of machineswith one or more lifting eyes, only hooksor shackles complying with local safetyregulations may be used. Never fastencables, chains or ropes to or through liftingeyes.

    Lifting hooks, lifting eyes, shackles etc.must never be bent and must always bestressed in alignment with the load-carryingaxis. The load capacity of the hoisting gearis reduced if the lifting force is applied at anangle to the axis.

    All bearing parts must be stressedvertically, as far as possible, for maximumsafety and optimum performance of thehoisting gear. If required, a support is to beinstalled between the hoisting gear and theload. Secure the load properly.

    When heavy loads are being conveyedby means of hoisting gear, it is imperativeto keep well clear of the load in order toavoid accidents.

    Never leave the load suspended on thehoisting gear.

    Acceleration or braking of the means oftransport must remain within the approvedlimits.

    The hoisting gear is to be set up in sucha way that the object is lifted vertically.Should this not be possible, precautionsmust be taken to prevent the load fromswinging. Thus it is possible to use twosets of hoisting gear, both with an angle ofinclination of not more than 30 to thevertical.

    Nominate experienced supervisors for thelifting process.

    Machines may only be hoisted correctlyusing hoisting gear in accordance with theinformation in the operating manual (limitstop points for heavy-lift facilities etc.)

    Only use a suitable transport vehicle withsufficient carrying capacity.

    Before or immediately after completionof loading, secure the machine / installationto prevent accidental shifting. Display anappropriate warning. Before putting themachine / installation back into operation,the securing devices must be dulyremoved.

    Parts to be removed for transportpurposes must be carefully refitted andfixed again before putting the machine /installation back into operation.

    When putting the machine / installationback into operation again, only proceed inaccordance with the operating manual.

    Transporting the complete unitMake sure that the air vessel is not under

    pressure.Lift and secure supporting gear.Make sure that the drawbar eye can

    move freely in the tow bar.Check to make sure that the drawbar is

    adjusted to the bar height of the towingvehicle.

    Check to make sure that the body isclosed and locked, and that the cable forthe rapid-emergency brake is connectedto the towing vehicle.

    Join up the connections of the air brake,if present.

    Check to make sure that the wheels areproperly tightened, that the tyres are in aroadworthy condition, that the tyre pressureis correct and that the brakes functionproperly.

    Connect the cable for the signallingand lighting fittings. Check the properfunctioning of the lighting.

    Release the handbrake.Before transporting the unit, always

    check to make sure that the accessoriesare firmly attached so that they can causeno accidents!

    When using public roads, tracks andspaces, observe the current trafficregulations, and if necessary make theunit roadworthy first!

    Never exceed the maximum towingspeed. Observe national regulations!

    Always switch on lights if visibility is poorand during lighting-up time!

    When going through underpasses,bridges, tunnels, overhead power lines,etc., always make sure that you haveenough clearance!

    Always keep a safe distance from theedges of foundation ditches andembankments!

    Do not travel across slopes transversely:always keep equipment and loads nearground level (for example, do not placethem on the bodywork).

    On descents, always adapt speed to thecircumstances! Never change into low gearduring the descent, but always beforehand.When leaving the driver's seat, alwayssecure the unit to make sure that it cannotroll away or be used without authorization!

    Avoid all operations that adversely affectthe stability of the unit.

    3.5 Installation on site / Starting /Normal operation

    Installation on site

    Besides the general technical operationin accordance with the regulations of thelocal authorities, it is essential that thefollowing guidelines be observed.

    Before switching on the machine /installation, or starting it up, make surethat nobody can be injured by themachine / installation as it starts up.

    The installation is to be set up in such away that it is adequately accessible andthat the necessary cooling is ensured.Never block the admission of air.

    The air intake is to be designed in sucha way that no dangerous admixtures(inflammable solvent vapors etc., butalso dust and other dangerous or toxicsubstances) can be taken in. This alsoapplies to flying sparks.

    The air intake is to be designed in such away that no loose personal clothing can bedrawn in.

    Make sure that the compressed air linefrom the compressor to the air network canexpand as a result of heat and cannotcome into contact with inflammablematerials.

    The compressed air line connected at theair exit of the unit must not be under strain.

    Compressed-air lines have to be markeddistinctly according to local regulations.

    If several compressors are arranged in asystem, manually operated valves have tobe installed so that each machine may beshut off individually. For the purpose ofshutting off pressurized systems, youshould never rely on the effectiveness ofreturn valves alone.

    Safety devices, protective covers, orinsulations mounted on the system mustnot be removed or modified in any way.

    3. Security Regulations

  • 68

    All pressure tanks located outside the unitwith an approved operating pressure higherthan atmospheric pressure and fitted withtwo or more pressure feed lines must beequipped with an additional safety deviceto automatically prevent the approvedoperating pressure from being exceeded bymore than 10%.

    Pipes and other parts with a surfacetemperature of more than 80 C must besuitably secured against contact andsuitably marked.

    Electrical connections must comply withlocal regulations.

    With compressors fitted with generators,use equipotential bonding systems for theprotection of persons.

    Install the machine so that it is ashorizontal as possible; a slight inclination ispermissible (see information in Chapter"Installation").

    Set up the machine in such a way that noinlets, outlets or gates are blocked, evenwhen the doors are open.

    Before disconnecting the machine fromthe towing vehicle, apply the handbrake.Disconnect the rapid-emergency brakecable and lighting cable, disconnect thelines of the air brakes, use chocks toensure that the machine does not roll away.

    If a machine with a combustion enginehas to work in a fire-risk environment, theunit must be fitted with a spark catcher.

    In dusty environments, set up themachine in such a way that the wind doesnot blow dust in its direction. Duringoperation in clean environments, theintervals for cleaning the air intake filterand the cooler elements are much longer.

    Do not install the machine directly infront of walls. Make sure that the warm aircoming from the engine and coolingsystems is not drawn into the air intakeunder any circumstances. Drawing thiswarm air in through the engine or coolerfan could lead to overheating; if it isdrawn into the combustion chamber, thiswill result in a loss of power.

    Never relocate the machine if externallines or hoses are connected to thedischarge valves, in order to avoid damageto the valves and/or collecting pipe andhoses.

    No force may be exerted on thedischarge valves, for example by pullingthe hoses or fitting additional equipment(e.g. a water separator, compressed airoiler, etc.) directly to the discharge valve.

    Make sure that:

    * All bolted connections have beentightened

    * All electrical wiring has been connectedcorrectly and is in good condition

    * The engine exhaust system isoperationally safe and that noinflammable material is in the vicinity

    * The wheel nuts are properly tightened;never exceed the specified torque.

    Cold-starting diesel engines with etherfuel systems

    The fuel used in these systems is highlyinflammable, toxic and poisonous. Avoidcontact with eyes and skin, and neverinhale vapors. Should you accidentallyswallow fuel, do not induce vomiting, butseek medical attention.

    Before using the ether cold-startingsystem, please read the instructionscarefully.

    Never use the ether cold-starting systemwhile the engine is running, as this canlead to serious damage.

    Wear suitable eye protection wheninspecting the system. Make sure that theopenings of containers, valves, or pipes arenever directed at yourself or at any otherperson during inspection.

    Never store ether containers attemperatures above 70 C.

    Normal operationBefore starting work, make yourself

    familiar with the working environment at theinstallation site. The working environmentincludes, for example, obstacles in theworking and transport areas, the carryingcapacity of the ground, and any necessarycordoning off of the building site from publictraffic areas.

    Take the necessary precautions to makesure that the machine / installation is onlyoperated in a safe, functional condition.

    Only operate the machine when allprotective devices, shutdown devices,sound-insulating equipment and extractionequipment is in place and working.

    Be careful: loose articles of clothing, hairor limbs can still be drawn in by revolvingparts.Verify regularly that:* All protective equipment is properly

    positioned and fixed in place* All hoses and/or pipes within the system

    are in good condition, are properly fixedin place and do not chafe

    * There are no leaks (fuel, oil or coolantleaks)

    * All bolted connections have beentightened

    * All electrical wiring is properly connectedand is in perfect condition

    * Safety valves and other pressure-reliefdevices are in perfect condition and arenot blocked, for example by dirt or paint

    * The safety devices all work properlyAll connected components must be of

    the correct size and be suitable for thespecified operating pressure andtemperature.

    Only use the correct type and size ofhose coupling and connection.

    Before blowing through a hose or air line,it is essential to hold the open end firmly.If the open end is not held firmly, it canwhiplash and cause damage or injury.

    Avoid any working methods that could beconsidered risky!

    Never play about with compressed air.Never direct compressed air onto the skin

    or towards another person.Never use compressed air for cleaning

    clothing. When using compressed air toclean equipment, work with extremecaution and always wear suitable eyeprotection.

    The compressed air produced by thesecompressors must not be used as breath-able air, unless it has been processedspecially for such an application inaccordance with the Safety requirementsfor breathable air.

    When breathing apparatus with cartridgesis used, make sure that the correctcartridge has been inserted and that itsservice life has not expired.

    Never use the machine in environmentswhere the possibility cannot be ruled outthat inflammable or toxic vapors may betaken in.

    Never operate the system at temperaturesand/or pressures below or above the valuesindicated in the technical data sheet.

    Persons working in environments orrooms in which the acoustic pressure is85 dB(A) or higher must wear ear muffs.Caution: this may impair communicationbetween persons. Warnings may not beheard. Inform supervisor.

    Shieldings and doors must be closedduring operation so that the flow of cool airwithin the housing is not deflected and theefficiency of the sound-insulating is notreduced. Doors and hoods may only beopened briefly.

    3. Security Regulations

  • 69

    With water-cooled combustion engineswith a closed cooling circuit, the cap of thecoolant recovery bottle must not beremoved before the system has cooleddown to ambient temperature.

    Never fill up with fuel while the engine isrunning. Make sure that fuel does not comeinto contact with hot machine parts.

    Do not smoke while filling up with fuel.Filling up at a pump can cause static

    electricity and possibly sparks. In order toavoid this, a ground cable must beconnected to the system while it is beingfilled up.

    The exhaust emissions of combustionengines contain carbon monoxide - a lethalgas. If a machine with such an engine hasto work in an enclosed room, the exhaustgases must therefore be conducted outof doors by means of a hose or pipe withan internal diameter of at least 100 mm.The use of extraction systems is highlyrecommended in test rooms for mobilemachines.

    Before connecting or disconnectinghoses, always close the compressor airoutlet valves. Before disconnecting a hose,always make sure that it is not underpressure.

    A hose connected to an air valve mustbe fitted with a safety wire for operatingpressures above 7 bars; it is in factrecommended that this safety deviceshould be used for pressures above 4 bars.The steel wire has a diameter of 8 mmand is firmly clamped to the hose at leastevery 500 mm. Both ends are fitted withcable lugs.

    Check the machine / installation forexternal damage and faults at least onceper shift. Any changes noticed (includingchanges in operating performance) mustbe reported immediately to the authority orperson in charge. If necessary, shut downand secure the machine immediately.

    In case of malfunction, shut down andsecure the machine / installationimmediately. Have malfunctions correctedimmediately.

    Observe the operating manual for start-up and shutdown procedures as well asinspection displays.

    3.6 Special jobs / MaintenanceCare

    Observe the setting, maintenance, andinspection work and intervals stipulated inthe operating manual, including informationabout the replacement of parts / partialsections. This work may only be carried outby specialists.

    Maintenance work, tests and repairsshould be carried out in a well ventilatedroom, away from heat, open flames, orsparks. Appropriate prohibition signs (fire,open flames, no smoking) must be put up.

    Loss of oil leads to a very slippery floor.Statistics have shown that many accidentscan be attributed to the installation ormaintenance of machines on oily floors ormachine components. For this reason,always start maintenance work by cleaningthe floor and the machine exterior.

    Inform operating personnel beforebeginning to carry out special work ormaintenance. Nominate a supervisor.

    After completing repair work, alwayscheck to see whether any tools, looseparts or cloths have been left in or on themachine, driving engine or drivingequipment.

    Maintenance and repair work is only to becarried out under the supervision of or by aperson qualified for this work.

    For all work concerning the operation,production adjustment, conversion, orsettings of the machine / installation and itssafety-relevant equipment, as well asservicing, maintenance, and repair,observe the operating manual for startupand shutdown procedures and theinstructions for maintenance work.

    All maintenance and repair work mayonly be carried out when the system is shutdown, or, with electrical systems, when themains power supply is switched off. Makesure that the equipment cannot beswitched on by accident.

    Whenever the machine/system iscompletely powered down for maintenanceand repair procedures, it has to besecured against unintentional power-onor the mains supply has to be cut offwith electrical systems.* Remove the ignition key, and / or* Put up a warning sign on the main

    switch Attention! Maintenance work.Close off the complete maintenancearea, if required.

    * Disconnect the starter battery.Individual parts and larger subassemblies

    must be carefully attached to the hoistinggear and secured in case of replacement.

    Only use suitable, technically perfecthoisting gear and load suspension deviceswith adequate carrying capacity. Keep clearof suspended loads.

    Before removing any part under pressure,separate the aggregate effectively fromall sources of pressure and release thepressure from the complete system.

    Never use inflammable solvents orcarbon tetrachloride to clean parts.

    Take precautions to avoid toxic vaporsfrom cleaning fluids.

    Absolute cleanliness is essential duringmaintenance and when carrying outrepairs.

    Only carry out maintenance and repairwork when the machine is located on aneven, stable base and is secured againstrunning away and against buckling.

    Only carry out inspection, maintenance,and repair work when the screwcompressor system is at a standstill and isnot under pressure.

    Protective devices, i. e. protective grids,may not be removed during operation.

    Caution while the screw compressor is inoperation.

    After the work has been completed,replace any protective devices that havebeen removed. Operation withoutprotective devices is not permissible.

    Working clothing should be close-fittingduring work on running screw compressorsystems.

    Maintenance

    During maintenance and repair work, thecontractor has to inform the personnelabout the dangers that can occur duringtheir work and about measures to avertsuch dangers.

    The personnel have to support allmeasures to improve safety at work.

    Safety devices for preventing oreliminating dangers must be servicedregularly and their functioning tested atleast once per year. Faults discovered mustbe corrected at once or reported to thesupervisor.

    Only use the correct tools formaintenance and repair work.

    Only use original spare parts.All maintenance and repair work may

    only be carried out when the system is shutdown, or, with electrical systems, when themains power supply is switched off. Makesure that the aggregate cannot be switchedon by accident.

    3. Security Regulations

  • 70

    Whenever the machine/system iscompletely powered down for maintenanceand repair procedures, it has to besecured against unintentional power-onor the mains supply has to be cut offwith electrical systems.* Remove the ignition key, and / or* Put up a warning sign on the main

    switch Attention! Maintenance work.Close off the complete maintenancearea, if required.

    * Disconnect the starter battery.Before removing or opening any part

    under pressure, separate the equipmenteffectively from all sources of pressure andrelease the pressure from the completesystem.

    For moveable machines support thetowing mechanism and axle withappropriate means if work is to be carriedout underneath the units (a jack is notsufficient).

    Observe the safety precautions for workon batteries.

    Pay attention to cleanliness. Prevent dirtfrom entering by sealing the parts andexposed openings with a clean cloth,paper, or tape.

    Before the aggregate is approved foroperation after maintenance or anoverhaul, make sure that operatingpressures, temperatures, and time settingsare correct and that the control andshutdown devices are working properly.

    The electric motor, generator, air filter,electrical components and controlequipment are to be protected against thepenetration of dampness - for examplewhen cleaning with a steam jet - bycovering or sealing them.

    Under no circumstances should thesound-insulating material be removed ormodified.

    Never use solvents with dangerousproperties for cleaning parts.

    Maintenance work, tests, and repairsshould be carried out in a well ventilatedroom, away from heat, open flames, orsparks. Appropriate prohibition signs (fire,open flames, no smoking) must be put up.

    Wear suitable eye protection wheninspecting the system. Make sure that theopenings of spray containers, valves,pipes, or atomizers are never directed atyourself or at any other person during theinspection.

    The fuel used in these systems is highlyinflammable, toxic and poisonous. Avoidcontact with eyes and skin, and neverinhale vapors. Should you accidentallyswallow fuel, do not induce vomiting, butseek medical attention.

    Should fuel come into contact with theeyes, or in case of eye irritation by vapors,flush eyes with plenty of clean water andseek medical attention.

    Every time a message is displayed orthere is a suspicion that an internal partof the machine has overheated, themachine must be shut down. Never openthe inspection cover, however, before themachine has cooled down sufficiently torule out the possibility of the oil vaporsigniting spontaneously when mixed with air.

    In order to avoid an increase in operatingtemperature, inspect and clean the heattransfer surfaces (cooling ribs etc.)regularly. Draw up a schedule for the mostsuitable cleaning intervals for eachmachine.

    Avoid damaging the safety valves andother pressure-reducing devices. Inparticular, make sure that they are notblocked through paint, oil carbon, ordust accumulation, which could impairthe effect of these devices.

    The insulation or protective shielding ofparts whose temperature may exceed80 C and which may accidentally betouched by personnel may not be removedbefore these parts have cooled down toroom temperature.

    Check the accuracy of the pressureand temperature displays regularly. If thepermissible tolerance limits have beenexceeded, then they must be replaced.

    Never carry out welding work or any otherwork that produces heat in the vicinity offuel or oil systems. Systems, which couldcontain fuel or oil, have to be completelydrained and cleaned, e.g. by means of asteam jet, before proceeding with the workto be carried out.

    Never carry out any welding work on anypressure tank or components underpressure, or modify them in any way.

    If work causing heat, flames, or sparkshas to be carried out on a machine, thesurrounding components must be protectedwith nonflammable material.

    Before dismantling or overhauling acompressor, engine, or any other machine,make sure that no movable part with aweight of more than 15 kg can move or rollaway.

    Machines whose main movement is backand forth must be moved at least once,rotating machines several times, in order tomake sure that there is no mechanicalmalfunction in the machine or in the drivingpart.

    Only experienced persons may becharged with slinging loads and instructingcrane drivers. These instructors mustremain within sight of the operator or be intouch with him via walkie-talkie or similardevice.

    During assembly work above bodyheight, use appropriate or otherwise safety-relevant climbing aids and workingplatforms. Do not use machine parts asclimbing aids! Wear safety belts whencarrying out maintenance work at greaterheights.

    Keep all steps, handles, railings,platforms, scaffolds, and ladders free ofdirt, snow, and ice.

    Before beginning maintenance andrepair, clean the machine, particularlycouplings and bolted connections, of oil,fuel, and special care products. Do not useaggressive detergents. Use lintfree clothsfor cleaning.

    After cleaning, remove all covers andseals.

    After cleaning, check all fuel, engine oil,and hydraulic fluid lines for leaks, looseconnections, chafing and damage. Correctany faults immediately.

    Always tighten bolted connectionsloosened during maintenance and repairwork.

    If it is necessary to dismantle safetydevices during machine set-up,maintenance, and repair work, the safetydevices must be reassembled and checkedimmediately after completing themaintenance and repair work.

    Ensure safe, environment-friendlydisposal of process materials as well asreplaced parts. Components containing oil,for example fine separators, and oils mustbe disposed of. Oil must not enter the soil!

    Safety precautions for work withbatteries

    The fluid contained in batteries is dilutedsulfuric acid which can cause blindness ifbrought into contact with the eyes, orserious burns if brought into contact withthe skin. For this reason it is essential towork with the greatest of care whenservicing batteries, e.g. when checkingbattery charge, and to take all necessarysafety precautions.

    3. Security Regulations

  • 71

    Always wear long-sleeved overalls, acid-resistant gloves and safety goggles.

    On charging a battery, an explosive gasmixture is formed in the cells, which canescape through the vent holes in thesealing caps. If ventilation is poor, a highlyexplosive atmosphere can form around thebattery, and can persist for several hoursafter charging.Thus:

    * Never smoke in the vicinity of batteriesthat are being charged or have just beencharged.

    * Put up prohibition signs for fire, openflames and smoking in workshops wherebatteries are charged.

    * Never interrupt a current-carrying circuitat battery terminals because of thedanger of spark formation.

    * Proceed particularly cautiously whenconnecting or disconnectingreinforcement cables or quick-chargecable clamps.

    When starting up using jumper cables orauxiliary batteries, first connect the positiveterminals and then the negative terminals.After starting the engine, first disconnectthe negative terminal (ground cable) andonly then the positive terminal. Disconnectthe auxiliary battery after the startingprocedure in order to avoid the risk of therelease of gas (explosion hazard).

    3.7 Instructions concerningparticular hazards

    Electrical EnergyOnly use original fuses with the specified

    amperage.In case of faults in the electrical power

    supply, shut down the machine / installationimmediately!

    Work on electrical systems or equipmentmay only be carried out by a trainedelectrician or by trained persons under theleadership and supervision of a trainedelectrician in accordance with thestandards of electrical engineering.

    Machine and system parts where service,maintenance, and repair work is beingcarried out must be switched off load, ifrequired by regulations. First check thedeenergized parts to make sure they areoff load, then connect to ground and short-circuit, and insulate neighbouring parts thatare under tension.

    The electrical equipment of a machine /installation must be inspected / testedregularly. Faults, such as loose con-nections or overheated cables, must becorrected immediately.

    If work has to be carried out on live parts,then call in a second person to operate theemergency stop switch or master switchwith overvoltage release. Cordon off theworking area with a red-and-white safetychain and a warning sign.

    Only use insulated tools.Keep an adequate distance between the

    machine/unit and overhead power lines!When working near overhead power lines,equipment must not come near the powerlines! Danger! Find out about the safedistance to be observed!After touching high-voltage lines:* Do not leave the machine.

    * Move the machine away from thedanger area.

    * Warn outsiders not to come closer ortouch the machine.

    * Make sure that the voltage is switchedoff.

    * Do not leave the machine until the linewhich has been touched or damaged,has been switched off load!

    When working with high-voltageassemblies, ground the supply cable aftervoltage has been isolated, and short-circuit the components, e.g. capacitors,with a ground rod!

    Gas, dust, steam, smokeOnly carry out welding, burning, and

    grinding work on the machine / installationwhen this has been explicitly permitted, asthere may be for example risk of fire and/orexplosion.

    Prior to welding, burning and grindingremove any dirt and inflammablesubstances from the machine/systemand its environment and ensure properventilation (danger of explosion)!

    Only operate combustion engines inproperly ventilated rooms. Ensureventilation is adequate before starting upin closed rooms.

    Follow the local regulations applicable atthe respective site of installation.

    Hydraulic and pneumatic systemsWork on hydraulic equipment may only

    be carried out by persons with specialknowledge of and experience in hydraulics.

    Check all lines, hoses, and boltedconnections regularly for leaks and visibledamage. Repair any damage immediately.It is essential that damaged parts should bereplaced! Spurting fluid can lead to injuriesand fires.

    Before beginning repair work, relieve thepressure in system sections to be openedand in pressure lines (hydraulic andcompressed-air lines) in accordance withthe descriptions of the subassemblies.

    Hydraulic and compressed-air linesmust be routed and fitted in accordancewith the regulations. Do not confuse theconnections!

    The fittings, length, and quality ofhoses must be in accordance with therequirements.

    Noise

    Sound-insulating equipment on themachine / installation must be in operativeposition during operation.

    Wear the prescribed personal ear muffs.Caution: this may impair communicationbetween persons. Warnings may not beheard. Inform supervisor.

    The power of perception may becomeadversely affected by the noise and bycarrying ear protection. Warnings may,therefore, not be heard. Circumspectbehaviour by all concerned is necessary.

    Noise, even when it is not very loud, canmake us nervous and irritated, and after alonger period of time our nervous systemcan suffer serious damage. For this reasona separate machine room is preferable, inorder to keep the noise from the machinesout of the workshop.

    Depending on the number of machines ina machine room, the noise generated canbe very loud. Depending on the level ofsound pressure in places where people arepresent, the following precautions must betaken:

    Below 70 dB(A): No special measuresrequired.

    Above 70 dB(A): Persons permanentlypresent in the room mustwear ear muffs.

    Below 85 dB(A): For occasional visitorswho are only in theroom briefly, no specialprotective measures arerequired.

    Above 85 dB(A): Noisy room. There mustbe a warning sign atevery entrance pointingout that persons enteringthe room - even if onlybriefly - must wear earmuffs.

    3. Security Regulations

  • 72

    Above 95 dB(A): The warning signs at theentrances must besupplemented by therecommendation thateven occasional visitorsmust wear ear muffs.

    Above 105 dB(A):Special ear protectorsadapted to the volumeand spectral compositionof the noise must beavailable. A warning signto this effect must be putup at every entrance.

    Make sure that sound propagatedthrough walls and frames does not causean excessive sound level in thesurroundings.

    Oils, Greases and Other ChemicalSubstances

    When handling oils, greases and otherchemical substances, observe the safetyregulations applicable for the product.

    Caution when handling process materials(risk of burning / scalding).

    Potentially-explosive environmentsThe operation of the compressor in areas

    where there is a risk of explosion is strictlyforbidden! (Exception: specially-madecompressors with the necessary technicalmodifications for use in such areas)Note

    CompAir accepts no responsibility for anydamage or injury caused by noncompliancewith these safety measures ornoncompliance with normal care andcaution during the handling, operation,maintenance or repair of this compressor,even if not expressly stated in thisoperating manual.

    3.8 Symbols and definitions

    Carefully read the OperatingManual before machine set-up andmaintenance.

    Never attempt to operate themachine without the safety devicemounted.

    Do not inhale any compressed airfrom the system.

    Never attempt to operate themachine with open or looseshielding.

    Attention Hot surface.

    Attention Pressurized part orsystem.

    Lifting spot

    Tie down point

    3. Security Regulations

  • 73

    Attention Hot and harmful exhaustgas.

    Attention Danger of electric shock.

    Do not step/stand on maintenancevalve or other parts of thepressurized system.

    Attention Maintain specified tyrepressure! (See ChapterForeword, specifications.)

    Protect the generator frommoisture. Do not clean with a water/vapor jet.

    Attention Do not use an etheraerosol

    Do not remove the Operating andMaintenance manual and manualholder from this machine.

    Attention Max. permissible noiselevel (See ChapterForeword, specifications.)

    3. Security Regulations

    1,5BAR

  • 74

    Fuel drain

    Oil filler plug

    Fuel

    Combined stop and emergency stopdevice

    Warning: Hot surfaces.Open the body lids no earlier than 30 minutes after the safety warning hasswitched off.

    A. WarningB. Parking brakeC. Correct position of the hand brake

    Condensation drain:Under very humid operating conditions the condensation should bedrained from the pressure tank every 24 hours.

    Pressure tank:Before topping up the oil, release all pressure and read the operatinginstructions.

    3. Security Regulations

  • 75

    3. Security Regulations

    Remove transportation braces before commissioning.

    Before connecting the tow bar or commencing to tow consult the operatingmanual

  • 76

    4. Construction and functional description

    Fig. 31. Screw compressor2. Instrument panel3. Pressure tank4. Oil cooler5. Oil filter (compressor)6. Air filter (compressor)7. Air filter (engine)8. Taps9. Hood

    10. Fuel tank11. Battery12. Diesel engine13. Chassis14. Tool oiler15. Crane ring16. Vehicle and chassis type identification

    number

    4.1 Construction

    Compressor and engineThe DLT 0702 series is a sound proofed

    mobile compressor system. The core is asingle-stage, oil-flooded screw compressor.The CompAir screw profile represents thestate-of-the-art. The air is deliveredpulsation-free.

    Frame and chassis

    The complete compressor unit ismounted on an easy-to-transport single-axle chassis. The chassis is equippedwith automatic overrun brakes andparking brakes, as well as a jockey wheeladjustable in height.

    Airflow

    Fresh air is sucked in through theadmission opening at the back of thecompressor. The air intake volume isair for the engine and for the compressortoo, as well as cooling air for the engineand for the oil cooler of the compressor.

    4.2 Functional description (see fig.4)Oil circuit

    The oil required for sealing and coolingthe rotors as well as for lubricating theroller bearings is injected into thecompressor (23) from the pressure tank(13), which is under system pressure. Thedifference in pressure between thepressure tank and the oil injection positionis approx. 1 bar. The oil hereby passes theoil cooler (20) and the oil filter (19). Theintake control valve (2) is fitted with a non-return function, so that when the system isswitched off, flooding of the air filter (1) isprevented.

    Air circuit

    The intake air flows through the air filter(1) and the suction control valve (2) into thecompressor (23). During compression, oil isinjected in order to lubricate, cool and sealthe screw rotors. The compressed air-oilmixture flows into the pressure tank (13).Centrifugal preseparation of the oil isensured through tangential entry into thetank.

    Any remaining oil is separated from theair in the fine separator.

    The compressed air is fed via the Venturinozzle (11) / the pressure retention valve(option) to the compressed air discharge.The venturi nozzle (11) effectively preventsthe system pressure from falling below theminimum operating pressure required forthe system to work properly. A temperaturemonitoring device (22, 6) as well as anoperational pressure manometer areintegral parts of the air circuit.

    The drive assembly is a medium-cooleddiesel engine, which drives the screwrotors of the compressor by a flexiblecoupling.

    Shielding (Body)The shielding consists of a low box

    mounted on a base-frame. A cover, whichcan be opened wide for servicing is fixed tothe base-frame. The opening of the coveris effectively supported by pneumaticsprings. The hook inside is for hanging upa load suspension device. The machinerests on rubber elements to preventvibrations and noise.

    For convenient assembly, all individualparts of the cover are screwed togetherwith machine screws. For the prevention ofcorrosion, the compressor body is fullygalvanised, electrostatically powder coatedand burnt at C 220. The sound absorbingmats are inserted and easy to be cleaned.

    13

    9

    15

    4

    1210

    6

    3

    7

    11

    16

    1

    5

    8

    2

    14

  • 77

    Regulation

    Note

    It is not possible to start up the compressorif there is insufficient fuel is available.

    Starting up: The control function isinactive at start up, i.e. as the system rises,the engine speed is lowered to idling andthe suction throttle closed. Once the dieselengine has warmed up, the throttle/speedcontrol is activated pressing the loadbutton.

    The throttle/speed control enables thevolume of air tapped (10) to be adjustedinfinitely between 0% and 100%.

    The control valve (2) is connected to theengine speed control lever over a secondset cylinder. When starting, the engine isset to full load and the control valve isopen. The compressor (23) starts toproduce and pressure builds up inside thecontainer (13). When exceeding theoperating pressure the P-controller (3)feeds the set cylinder of the controller withair. Each change of the pressure at theadmission opening causes a proportionalpressure raise at the exit. This controlpressure operates the control cylinder.Over the calibrated opening of the exhaustair nozzle (5) the control air gets partly intothe atmosphere and any condensate will belet off. The throttle valve closes (throttle-type governor) and the engine speed willbe lowered (speed control). That way theair volume will be adjusted variable to therequired air. If the air output drops down tozero, the throttle valve is completely closedand the engine runs under idle runningspeed. Over the exhaust air nozzle (5) thesucked in air will be let off over a leakagecleft. When the pressure of the containerdrops down the control pressure of thecontroller drops down too; the throttle valveopens and the engine speed will increase.

    When turning off the engine the backlashflap inside the controller will be closedthrough the system pressure. The releasevalve (3), which closes parallel to theengine lifting magnet, looses power andopens. The container pressure drops downto zero.

    4. Construction and functional description

  • 78

    Fig. 4 135 028 74

    4. Construction and functional description

    4.3 System description

    1. Air filter2. Intake control valve3. Control unit (proportional controller +

    start-up without load)4. Release valve5. Nozzle controller6. Pressure gauge8. Oiler reservoir9. Oiler valve

    10. Taps11. Venturi nozzle12. Safety valve13. Pressure tank14. Fine separator17. Orifice, evacuation line

    19. Oil filter20. Oil cooler compressor21. Oil cooler engine22. Temperature switch23. Compressor24. Diesel engine27. Engine actuating cylinder29. NozzleGenerator option28. Solenoid valveGenerator with pressure reductionoption28. Solenoid valve41. Solenoid valve42. Pressure retaining non-return valveOption Heat exchanger25. Heat exchanger26. Oil temperature control

    Option oil temperature control30. Oil temperature controlOption After cooler31. Cooler32. Condensate separator25. Heat exchanger26. Oil temperature control35. Backlash valve36. Extraction lever oil-free compressed airOption filter37. Filter combinationOption clean air38. Pressure control39. Activated carbon filter40. One-hand coupling

  • 79

    Fig. 5 135 033 74

    4. Construction and functional description

    4.4 Wiring diagram

    S1 Main switchS2 Start switchS3 Signal interrupt switchS4 Engine temperature switchS5 Compressor temperature switchS6 Engine oil pressure switchS7 Fuel shortageOptional:S8 Generator automatic idling control

    (optional)S9 Generator pressure reduction (optional)

    Y1 Solenoid actuatorY2 Solenoid valve for pressure relief

    Optional:Y3 Solenoid valve generator automatic

    idling control (optional)Y4 Solenoid valve generator pressure

    reduction (optional)Y5 Solenoid valve aftercooler condensation

    drainage (optional)

    D1 DiodeOptional:D2 Fuel shortage shut down

    H1 Battery charge pilot lampH2 Fault pilot lampH3 Fuel shortage

    K1 Relay - faultK2 Relay - fuel shortageK3 Relay start-upK4 Relay start lock

    G1 Three-phase generatorG2 Battery

    M1 Starter

    P1 Hours of operation counter

    F1 Fuse 5 AF2 Fuse 5 A (generator)

  • 80

    105 580 74

    rear fog lamp

    right taillamp

    right indicator lamp

    right stoplamp

    left stoplampleft indicator lamp

    left taillamp

    ground

    white

    black

    yellow

    red

    green

    brown

    blue

    Terminal Diagram DIN ISO 1724

    Connector Circuit connector

    blue (54 G)

    brown (58 R)

    green (R)

    red (54)

    yellow (L)

    black (58 L)

    white (31)

    4. Construction and functional description

    4.5 Terminal Diagram DIN ISO 1724

    Fig. 6

    The terminal diagram is designed for a voltage of 12 Volts!

  • 81

    5.1 Transport

    Fig. 7

    DangerMake sure to check the torque after50 kilometers following wheel mountingand at regular intervals.Tighten wheel nuts or screws evenly ina diagonal sequence to the specifiedtorque using a torque wrench.

    Replacing the trailer coupling ringThe coupling arrangements which can beused:* Trailer coupling ring RD 40* Coupling 50 dia.* Coupling ring 2" dia. (only for UK)* Coupling ring 68 x 25 dia. (only for

    France)A different coupling unit in the form of a

    complete kit may be ordered, if necessary.Replacing the trailer coupling ring ispermitted only if proper fitting is carried outby an inspectorate for the sector coveredby the Regulations Authorizing the Use ofVehicles for Road Traffic (e.G. the TV -Technical Inspectorate, DEKRA - GermanMotor Vehicle Monitoring Association, etc.).The inspection station provides a fittingcertificate to be kept with the vehicledocuments.

    DangerThe screw compressor may only betransported on public roads if* The machine group (engine) is not

    running,* The pressure tank is not under

    pressure,* The shieldings are closed,* The blocks are firmly hooked in

    place,* Hoisted and secured tail wheel,* The tyres and brakes are

    operationally safe and roadworthy,

    * The lighting is fully functional.Never exceed the maximum towingspeed! Danger! Observe nationalregulations!Please also observe the safetyinstructions in Chapter 3 on the subjectof transporting.

    Before transporting the compressor,check to make sure that the drawgear ofthe towing vehicle and the drawbar eye ortrailer hitch ball connection are alignedexactly to each other.When transporting the screw compressorwith a vehicle, the following points must beobserved:* The shieldings are closed.* The blocks are firmly hooked in place.* The support(s) is(are) retracted and

    locked in position (jockey wheel).* Tow bar connected to the towing vehicle,

    coupling cable connected to trailer.* The drawbar is adjusted to the height of

    the towing vehicle.* Connect the contact-breaking cable to

    the towing vehicle. Raise and secure thesupporting device.

    * Connect the electrical connecting cablebetween the vehicle and the screwcompressor.

    * Check the lighting (tail lights, brake lights,indicator lamps, and rear fog lights).

    * Check to make sure that the wheels areproperly tightened, the tyres are in aroadworthy condition and the tyrepressure is correct (danger ofaccidents).

    When parking the compressor, use thesupport or the jockey wheel to secure thecompressor in a horizontal position. Applythe parking brake. Use chocks to ensurethat the machine does not roll away.

    Attention

    Always keep a safe distance from theedges of foundation ditches andembankments! Do not travel acrossslopes transversely.

    5.2 Link up breakaway cable

    If the towing connection becomesuncoupled, the trailer is braked by thebreakaway cable. Put the breakaway cablein the eye provided or wind it around thetowing collar and hitch it up to the cablewith the snaplink.

    The breakaway cable must be attached ina way that ensures that even on extremelysharp bends there is no danger ofactivating the locking brake.

    Fig. 8

    5.3 Loading/Relocation

    Fig. 9

    DangerOnly use hoisting gear (e.g. crane) withappropriate lifting capacity for the loadsoccurring!Only use the correct suspension gear!Keep clear of the swiveling range of thehoisting gear!Keep clear of suspended loads!All loose parts that could fall downduring hoisting must first be removedor secured; pivoting parts, like doors,towbars, etc. must be secured in sucha way that they cannot move.Never leave the load suspended on thehoisting gear. Acceleration or brakingof the means of transport must remainwithin the approved limits.Please also observe the safetyinstructions in Chapter 3 on the subjectof loading.

    Attention

    Do not attempt to use a crane hook orsimilar load suspension devices directon the lifting device to avoid damagesto the lifting device!

    5. Transport and installation on site

  • 82

    5. Transport and installation on site

    A A A

    B B

    A = B = 1,5 m

    B

    Use proper hoisting gears only such ashoisting straps in compliance with DINstandard 61360 with proper lifting ca-pacity for connecting the loadsuspension device (e.g. crane) and thelifting device.Only deploy load bearing equipmentwhich corresponds to the safetyinstructions for lifting gear.Use a transport harness compliantwith local regulations for transportingby helicopter. The eyes provided maynot be used for this purpose (max.acceleration if the eyes are used = 2 x g)Never lift up or lash down the unit usingthe shieldings!Never relocate the machine if externallines or hoses are connected to thedischarge valves, in order to avoiddamage to the valves and/or collectingpipe and hoses.When loading, the following points must beobserved:* Secure the load suspension device or

    the hoisting gear in the lifting device ofthe screw compressor.

    * When hoisting the compressor, set upthe hoisting gear in such a way that thecompressor, which must be set uphorizontally, is lifted vertically.

    * Only relocate the compressor by itself.* Raise and lower the compressor

    carefully.* After relocating, remove the load

    suspension device or the hoisting gearfrom the lifting device.

    * Tie down the compressor on the cargoarea of the means of transport.

    * Only tie it down at towbar and wheelaxles.

    * When the chassis is being dismantled,the shieldings with machine group mayonly be supported under the base frame.

    5.4 Installation on site

    Fig. 10

    DangerThe air intake must be positioned insuch a way that loose personal clothingcannot be drawn in.Make sure that the pressure pipe fromthe compressor to the aftercooler or theair system can expand as a result ofheat, and that it does not come intocontact with inflammable materials.The air intake is to be designed in sucha way that no dangerous admixtures(inflammable solvent vapors etc.,but also other dangerous or toxicsubstances) can be taken in. This alsoapplies to flying sparks.Pipes and other parts with a surfacetemperature of more than 80 C must besuitably secured against contact andsuitably marked.The operation of the compressor inareas where there is a risk of explosionis strictly forbidden! (Exception:specially-made compressors with thenecessary technical modifications foruse in such areas)Please also note the safety instructionsin Chapter 3 on the subject ofinstallation on site.

    Location

    The complete system is to be set up insuch a way that it is easily accessible andthat the required cooling is guaranteed.Never block the air intake. Ensure that theentering of moisture and dirt together withthe intake air is kept to a minimum.

    The compressor is to be set up awayfrom walls.

    Attention

    The screw compressor is to be set up insuch a way that no air reflection cantake place, i.e. neither waste air norexhaust emissions may be drawn in; thesame applies to dangerous admixturesto the air. Drawing this waste air in couldlead to overheating and a loss of power.The compressor must be set up in ashorizontal a position as possible. Maximumpermissible inclination during operation:* In direction of pull: 15 degrees* Backwards: 15 degrees* To the right and to the left: 15 degrees

    Fig. 11

    Attention

    Greater inclinations endanger theoperating reliability of the screwcompressor.

    When setting up the unit on ground that isnot horizontal, or with a variable angle (seeoperating instructions) please consultCompAir.

    Set up the machine in such a way thatno inlets, outlets or gates are blocked,even when the doors are open. Beforedisconnecting the machine from the towingvehicle, apply the handbrake. Disconnectcontact-breaking cable and lighting cable,uncouple air brake lines.Secure wheels with chocks.

    Note

    In dusty environments, set up the machinein such a way that the wind does not blowthe dust in the direction of the machine.During operation in clean environments,the intervals for cleaning the air intake filterand the cooler elements are much longer.

    Attention

    No force may be exerted on the dis-charge valves, for example by pullingthe hoses or fitting additionalequipment (e.g. a water separator,compressed air oiler, etc.) directly at thedischarge valve.

    Temperatures/air humidityInstall the compressor in a location with

    maximum possible frost protection. Thesuction air temperature must be within therange specified on the data sheet.

    Attention

    When the system is deployed at hightemperatures (+40 C and above) andhigh air humidity (higher than 90 %) anoil temperature controller (optional) isrequired. For operation involving longperiods of idling and/or low partial loadsan oil temperature controller is alsorequired.

  • 83

    Altitude

    For operation at an altitude above1,000 m, the compressor and engine mustbe adapted (modified design).Note

    Particularly in case of installation out ofdoors and at night, observe fuel tempera-ture. At temperatures below 0 C, summerdiesel fuel tends to precipitate and blockthe fuel filter. In this case use winter dieselfuel.

    5. Transport and installation on site

  • 84

    6.1 Checking oil levels

    6.1.1 Checking the oil level in thepressure tank

    Fig. 121 Inspection glass2 Oil filler plug

    DangerOnly check the oil level when the engineis at a standstill and the compressor isnot under pressure.The pressure tank may be underpressure and the oil may be hot.Risk of scalding! Spill no oil!Check for leaks.Proceed as follows:* Before checking the oil level in the

    engine and in the compressor ensurethat the vehicle is standing horizontally.

    * Ensure that the screw compressor hasbeen out of operation for some time.

    * Check oil level in the inspection glass* The oil level must be in the middle of the

    visible range.* Correct as required.

    Attention

    After a short test run, the oil levelmust be in the middle of the visiblerange. For oil specifications, seerecommended lubricants, Chapter 8.1.

    6.1.2 Checking the oil level in the engine

    Fig. 13

    DangerOnly check the oil level when thecompressor engine is at a standstill.Spill no oil! The oil may be hot. Riskof scalding!Check for leaks.Proceed as follows:* Ensure that the screw compressor is

    standing horizontally.* Ensure that the screw compressor has

    been out of operation for some time. * Unscrew dipstick.* The oil level should be as near as

    possible to the upper dipstick mark.* Correct as required.* Screw in dipstick.* Close oil filler.* For oil specifications, see Engine

    Operating Manual.

    Attention

    After a short test run, the oil level mustnot be above or below the upper orlower dipstick marks. For oil specifi-cations, see engine instruction manual.

    6.2 Battery

    Fig. 14

    DangerWhen working with battery acid (electro-lyte), wear acid-resistant goggles,gloves and apron.The gases released by the battery areexplosive. Avoid sparks and open firesin the vicinity of the battery.Do not allow acids to come into contactwith skin or clothing. Wear safetygoggles.Place no tools on the battery.

    The battery is filled and charged inaccordance with DIN 43539. The battery isfastened with clamping strips.

    T